Done!
EDIT 2013-10-27 - WARNING
Thanks to feedback from other forum members we've learned that the bar that the third row seats are mounted on also serves as a brace that adds to the body rigidity and improves the vehicle handling and possibly adds to the crash resistance. We've also learned that the police version of the Explorer, the Interceptor, has an X-Brace in place of the third row and is actually available for purchase. Benny from the Levittown Ford Supercenter, a forum member, came forward with this information:
Ford X-Brace at the Levittown Ford Supercenter
Therefore, unless you opt to purchase and install this brace, removal of the third row is NOT recommended. Please follow this thread to the end to learn more.
ORIGINAL POST
OK, so I did it. I have 2013 Sport with manual third row seats. Here are the steps as I did this.
WARNING: There is some possibility of breaking stuff, mainly the pins and the snaps which will make the panels loose after remounting them. Also, there are few cables to be unplugged, if you pull the panels too quick and too far you can rip these cables out. By removing the panels you will expose lots of guts with some cables, tubing, ducts, etc. which can be damaged when removing the seat. The seat is heavy and there isn't a lot of wiggle room.
WARNING: Ask your dealer first if they will give any trouble in terms of warranty and support if you go ahead with this. This doesn't alter the vehicle in any way that might have any effect on the function of the vehicle, but if your dealer wants to be a jackass they might give you hard time.
So, yeah, be careful. I take no responsibility. None. Whatsoever. Nada! If you break something, scratch something, or hurt yourself, your wife, kid or your dog you will be the one solely to blame. Seriously. Yeah.
NOTE: You will need metric wrenches. I was somewhat nervous doing this and forgot few details, I think the nuts that hold the seat are 17mm, the one that holds the seatbelt is 16mm an those at the front support were 14mm. Anyway, if you have a regular metric set that goes up to 20mm you will be OK. A ratcheting wrench would help a lot (even better with an extension) to undo the four large bolts that hold the seat. They're in tight spots and there is very little room, you can only move the bolts by very little each time so if you have to reposition a regular wrench every time it'll take a very long time and be very frustrating to do.
NOTE: Pull the panels slowly and gently, I was amazed how weak some of the tabs looked, I think I got pretty close to breaking some!
NOTE: I bought a set of upholstery and panel removal tools from Auto Zone. I have weak hands and fingers (computer geek, LOL) so pulling the panels was difficult for me. These tools are plastic (nylon?) so they won't scratch the panels, but they will make it easier. See the pictures.
NOTE: You don't have to remove the gate seal. You will be able to tuck the panels under the seal when putting everything back together. It would actually be more difficult to mount the seal back than tuck the panels under it.
Here you go:
* Examine the seats, fold them and unfold them and look under the front panels/covers to familiarize yourself with the functioning of the front support brackets.
* Fold the second and third rows, take everything out of the cargo area.
* Remove the rubber inserts from the storage compartments on the panels, they're sure to fall off when you flip the panels later.
* I removed the spare wheel, I was afraid that I can bend or break the cover if I step on it.
* Unscrew the cargo hooks. Two on each side. They're plastic, you can do this by hand. I could LOL
* Remove the piece that says "REMOVE FOR SPARE TIRE". There are two screws at each end on the inside. Be careful, there are several small plastic tabs along this piece that look like they could break off.
* Remove the panel that sits atop the rear bumper. Just pull straight up. There was a cable there, not sure what it was for (see pictures). Some kind of antenna? Hmm... Google says it's keyless entry antenna. OK.
* Remove the steps/covers on the bottom of the rear door wells. Pull them straight up.
* Start pulling the right side panel, start in the rear (see the pictures for tab locations), then go to the front, behind the second row. Once you un-snap these two areas it'll be easier to un-snap the middle. There were no cables on the right side. Subwoofer is mounted to the body, nothing is connected to the panel (see the pictures).
* Move the panel away enough so you can reach inside and unscrew the bolt that holds the third row seatbelt anchor.
* Pull out the third row seatbelt through the opening in the panel and allow it to retract.
* Turn the panel over and lay it flat, interior facing up, on the folded second row. I have the inflatable second row seatbelts so I didn't want mess around with them. You can easily rest both panels across the second row without removing them from the car, with the second row seatbelts still threaded through them.
* Repeat for the left side panel. On the left side, there is a cable for the 12V power outlet (see the pictures). Lay the panel on top of the right side panel across the second row seats.
* Now, you can remove the rear pillar covers, they're held by one screw each, then pull them off. Be careful, there are speaker wires in each and they need to be disconnected! Sorry, I didn't take any pics of this step, but it was pretty easy. You should easily see the single bolt that holds them, then they come off easily. Avoid the temptation of letting the panels hang from these wires
I actually decided not to remove the seatbelts. I just wrapped the buckles and anchors (with bolts) in foam, so they won't rattle, then wrapped that with electrical tape and tucked them up inside the pillar and put the panels back on.
* NOW, MAKE SURE YOU HAVE PLENTY OF SPACE TO GET THE SEATS OUT AND THAT THERE IS NOTHING IN THE CARGO AREA! They are heavy, I figure 50lbs, and they move and flap around independently from each other which makes them a little of a pain in the butt to get out. You can't separate them, they're one assembly. I did it by myself, but it would be much easier for two people.
* OK, so now undo the large bolts on the sides. They're really in tight! Get them out all the way.
* Slowly and gently move the seat assembly out. Be careful not to scratch anything. In my model there was lots of tubing and wires on the left, so be careful not to bend or damage anything. I forgot the details (the process was a bit scary for me and I was nervous) but you will need to lift the backs (unfold the seats partially) a little bit in order for the fronts of the seats to disengage from the front support brackets, or you won't be able to pull the seats rearwards.
* Once the seats are out, undo the four bolts holding the front support brackets and remove them. The bolts holding those brackets appear to be permanently attached to the car's body. The only way to remove them would be to cut them off. I wanted this process to be 100% reversible so I can put the seats back if I needed to. So I will get some caps for these bolts. I think I saw something like that in hardware store: a threaded, rounded nut that protects the end of the bolt and then I will put some carpet over that area.
* That's it!
* To put everything back, just reverse the process. Don't forget to plug the wires in and don't forget to tuck the panels under the door seal and don't forget the rubber inserts for the storage compartments. Putting it all back was actually more tricky and took longer than taking everything out. You have to align the pins in order to snap panels in place. I found that I had to snap the middle in first and then front and rear. Just be patient, take your time, don't force anything in. If aligned properly everything should snap in easily. If something is not going in, then it's not aligned and you will break tabs or pins by forcing it in.
PICTURES:
